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Old 08-26-2012, 06:22 PM   #1
klm4755 OP
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Joined: Jun 2006
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DIY...Fluid container external attachment to pannier step-by-step

Enclosed is a step by step outline to create a fail-safe strap and bracket system to attach fluid containers to the rear of a happy trails panniers.

The bottles to attach. They carry 27 oz of liquid, and are fully stainless steel. From Klean Kanteen

Even the cap is stainless steel, the fluid is not in contact with the seal

want to mount here on the pannier

First I'll make the base, the container is 2.75 inch in diameter, circle template is used for scribing the base size

mark and cut, aluminum base, .050 inch gage

sand base to final size

deburr edge of base with this tool

quick size check

need 6x strap attach connectors

drill

cut to size, and deburr

trim base bracket to pannier

sand 220 grit and primer all parts with 2x coats

counter sink to accept flush fastener

need nylon webbing

trim to rough size to attach bottle

paint straps and plastic buckles

All parts painted with Krylon ultra flat paint

base bracket fastened

ACU camo base bracket

Attach nylon webbing on pannier with Al strap connectors, Key is to form large melted end on webbing

Attach mid-way up bottle

quick fit check, can cinch up pretty tight

install base plate, fluid container will rest on base bracket

Add top strap to thread thru bottle cap, sew with plastic buckle with nylon thread

finished product

view without bottle

Another view with buckles engaged

Bottle attached, note fail-safe design, One strap can fail, although not likely, but the bottle remains attached to pannier

Bike rear view

Enjoy...
Observations:
1. Easy, custom install
2. Costs of straps, buckles and al about $6.00
3. The only fluid planning to carry is water
4. No issues after ~1,000 miles
5. Not sure the value of locking bottles to bike. Don't think anyone would mess with them.
Keithm
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Old 08-28-2012, 07:33 PM   #2
klm4755 OP
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Here is a close-up of strap melted end, I used a soldering iron to form the Blunt end to restrain the webbing in the aluminum tie down

off-set side view of strap attach
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Old 08-28-2012, 07:45 PM   #3
Jnich77
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I absolutely love it... wait, when the army changes to "Milti-cam" are you going to redo the bike?
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Old 08-28-2012, 08:22 PM   #4
Unstable Rider
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I think I know that bike.....

I am a huge fan, not a hater.

You have mad ambitions (mad skills).

+1 brother.

You going to port some fuel in em?

I have some Agri-tool tubes and I have carried a bit of gas in one of those metal drink bottles like you got there, at least the largest one that fit the big Agri-tube. Never had it leak or drip. Carry a bit of oil in another on trips. Yes, I drive a KLR....

Going to rig some on an old Honda ATC I have for deer hunting...
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Old 08-29-2012, 11:35 AM   #5
klm4755 OP
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Quote:
Originally Posted by Jnich77 View Post
I absolutely love it... wait, when the army changes to "Milti-cam" are you going to redo the bike?
Not likely, although the ACU digital desert camo part of the bike can be removed, it would be a couple day work to re-bond new camo material.
Keithm
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Old 09-22-2012, 05:45 PM   #6
klm4755 OP
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Quote:
Originally Posted by Unstable Rider View Post
I think I know that bike.....

I am a huge fan, not a hater.

You have mad ambitions (mad skills).

+1 brother.

You going to port some fuel in em?

I have some Agri-tool tubes and I have carried a bit of gas in one of those metal drink bottles like you got there, at least the largest one that fit the big Agri-tube. Never had it leak or drip. Carry a bit of oil in another on trips. Yes, I drive a KLR....

Going to rig some on an old Honda ATC I have for deer hunting...
Right now the containers are just full of water, maybe fuel in the future
Keithm
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Old 09-26-2012, 08:32 AM   #7
newcastleadam
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Been awhile since I've seen you post up, glad you're back. Always enjoy your threads
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Old 09-26-2012, 08:32 PM   #8
DirtyOldMan
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Originally Posted by newcastleadam View Post
Been awhile since I've seen you post up, glad you're back. Always enjoy your threads

Yeah, I always read em, even if I have no interest in the finished product, the process and description are always top notch.

TV show?
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Old 09-29-2012, 06:55 PM   #9
klm4755 OP
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Quote:
Originally Posted by DirtyOldMan View Post
Yeah, I always read em, even if I have no interest in the finished product, the process and description are always top notch.

TV show?
Thanks...Always busy here tinkering...I added another Stainless Bottle to the left Pannier. This brings the total exterior fluid level to 81 oz.

Added bottle

Rear bike view

centered rear View.
Enjoy!
Keithm

klm4755 screwed with this post 09-29-2012 at 07:08 PM
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Old 10-01-2012, 04:20 AM   #10
hardybaker
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?????

Where did you buy those Allen headed fasteners?
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Old 10-03-2012, 10:48 AM   #11
staikosn1
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Excellent DIY
Too much camo.

Grats mate.
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Old 10-03-2012, 03:22 PM   #12
Dubl-A
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Now that is cool Bro! Nice job
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